Building material



Jan. 1, 1946. P. M. sNYDER BUILDING MATERIAL Filed Aug. 23, 1941 Patented Jan. 1,. 1946 BUILDING MATERIAL Purdum M. Snyder, Ben Avon. Pa., assigner to H H. Robert son Company, `corporation of Pennsylvania Pittsburgh, Pa., a

Application aucun! 2s, 1941,` seran No. 40am for. 15s-45.9)

8 Claims.

This' invention relates to a protected metal article for building purposes and to a method of making the same.

The object of the invention is to provide a novel and `superior protected metal article of the type wherein the metal article is protected b'y one or more bituminous coatings and impregnated fibrous layers, wherein the bituminous coatings and'lmpregnants are compounded to impart to the protected-metal' article the ability to'prevent the rapid propagation of flame when the article is subjected to the direct action of a'flre.

With this obiect in view,and such others as may Vhereinafter appear, theV invention consists in the protected metal article and in the method of making the same hereinafter described and particularly defined in the claims at the end of this specification.

In the drawing, Fig. 1 is a cross-sectional view of a protected metal article embodying the invention; and Fig.' 2` is a similar view of a modified form of protected metal article also embodying the invention.`

Referring now to Fig. 1, the protected metal article disclosed therein comprises a metal article il, preferably a 4metal sheet such as an iron or steel sheet. The metal sheet lil has secured to the opposite surfaces thereof layers I2 of fibrous material, preferably by an interposed body of bituminous material il. In practice the metal sheet il lis passed through a molten bath of the bituminous material Il and the fibrous layers applied before the bituminous material of the enveloping coat has solidified to thereby adhesively afiix the fibrous layers to the metal sheet. The fibrous layers i2 may be applied in offset relation to permit' the opposite marginal portions I5, I 8 oi' the opposed fibrous layers to be wrapped around the side edges of the metal sheet in the manner illustrated in Ii'ig. 1, and adhesively afnxed to the op1 posite surfaces of the fibrous layers. To further weather-proof the protected meta1 article, an outer protective coating Il of bituminous material may be provided forming aweather-proofing envelop for the protected metal article.

`The protected metalarticle thus far described mail, exceptas hereinafter pointed out, comprise the protected metal article forming the subject matter of United States patent to Robertson No. 1,217,755. to which reference is made.

Referring to Fig. 2 which illustrates a different embodiment of the invention. the protected metal .article illustrated therein comprises a metal sheet il haringone or more layers of fibrous material i! affixed to the opposite surfaces of the metal sheet Ilby an interposed layer 2l of metal adil of protective bituminous material as above described in connection with the article shown in Fig. 1.

In order to impart to the protected metal articles illustrated in Figs. 1 and 2 the ability to prevent rapid propagation of flame when the protected metal article is subjected to the direct action of a fire, it has been found that the bituminous materials employed as the impregnants of the fibrous layers I 2 in such structures and as the coating i4 in the structure shown in Fig. 1 are rendered flame retarding by the incorporation in such bituminous materials of at least one and preferably of several of the metallic soaps selected from the group consisting of the soaps of the metals manganese, iron, zinc, chromium, cobalt, aluminum, magnesium and barium. The bituminous materials for the production of such coatings and impregnants may and preferably will comprise those now commercially used for such purposes in the production of the protected metal articles under the Robertson and Comnan patents above referred to, and it is recommended that an amount of soap be incorporated varying from three to fifteen per cent.

Of the metallic soaps above referred to it has been found that the soaps of iron, zinc. aluminum and barium impart to the bituminous composi-` tions the maximum degree of flame retardance.

The barium soaps have been found to be patticularly eective from a flame retarding stand-` point. However, the barium soaps are not readily dispersed in asphalts by simple mixing and fluxing together. In an effort to find a method whereby this could be accomplished, it was found that the barium soaps could first be mixed with other soaps which were readily dispersed by simple mixing and iiuxing, and then in such combination could readily be dispersed in asphalte.

It was found that parts of a barium soap and 50 parts of a zinc soap when mixed together, and then added to anv asphalt or a bituminous combination, that nre retarding properties approximating the en'ectiveness of a manganese soap could be protected metal obtained, when added in approximately the same proportions. Percentages required to produce materials of commercial value fall within the range of 4 to 12%. In practice we have found that 6 to 12% is adequate.

If it is desirable to incorporate in the bituminous compounds, for purposes of compounding technique, any waxes, resins or mixtures thereof, it is recommended that such materials be utilized in proportions not to exceed 35% of the entire base as a satisfactory degree of flame retardance has not been experienced utilizing metallic soaps in bituminous materials embodying more than 35% of waxes, resins or mixtures thereof.

For some purposes I have found that combinations of several soaps may be used with advantage, particularly to obtain maximum effectiveness with respect to flame retardance. For example, it has been found that the addition of 3% iron stearate to an asphalt saturant or finisher for the production of code wire and embodying 8% of a barium zinc soap combination produces a bituminous composition which possesses very eiiicient flame retarding characteristics. Other soaps may be included as above described, such for example, as minor proportions of aluminum soaps, with barium and zinc soap combinations.

This application is a continuation in part of my application, Serial No. 183,160, filed on J anuary' 3, 1938.

Having thus described the invention, what is claimed is:

1. A protected metal article comprising a metal article provided with a laminated protective coating having a fibrous layer affixed to the metal article by an interposed adhesive layer, and an outer bituminous layer covering the fibrous layer, said outer bituminous layer having incorporated therein at least one metallic soap insoluble ln Water and comprising a soap selected from the soaps of the group of metals consisting of iron, zinc, aluminum, and barium, in an amount in the range of three to fifteen per cent by weight of the bituminous composition, said flame retarding bituminous composition being further characterized by its ability to maintain substantial predetermined physical characteristics upon cooling after having been subjected to heating to elevated temperatures.

2. A protected metal article comprising a metal article provided with a laminated protective coating having a fibrous layer aillxed to the metal article by an interposed adhesive layer, and an outer bituminous layer covering the fibrous layer, said outer bituminous layer having incorporated therein at least one metallic soap insoluble in water and comprising a soap selected from the soaps of the group of metals consisting of manganese, iron, zinc, chromium, cobalt, aluminum, magnesium, and barium, in an amount in the range of three to fifteen per cent by weight of the bituminous composition, said flame retarding bituminous composition being further characterized by its ability to maintain substantial predetermined physical characteristics upon cooling after having been subjected to heating to elevated ternperatures.

3. A protected metal article comprising a metal article provided with a laminated protective coating having a fibrous layer affixed to the metal article by an interposed adhesive layer, said flbrous layer being impregnated with a bituminous composition having incorporated therein at least one metallic soap insoluble in water and comprising a soap selected from the soaps of the group of metals consisting of iron, zinc, aluminum, and barium, in an amount in the range of three to fifteen per cent by weight of the bituminous composition, said flame retardlng bituminous composition being further characterized by its ability to maintain substantial predetermined physical characteristics upon cooling after having been subjected to heating to elevated temperatures.

4. A protected metal article comprising a metal article provided with a laminated protective coating having a fibrous layer affixed to the metal article by an interposed adhesive layer, said fibrous layer being impregnated with a bituminous composition having incorporated therein at least one metallic soap insoluble in water and comprising a soap selected from the soaps of the group of metals consisting of manganese, iron. zinc, chromium, cobalt, aluminum, magnesium, and barium, in an amount in the range of three to fifteen per cent by Weight of the bituminous composition, said flame retarding bituminous composition being further characterized by its ability to maintain substantial predetermined physical characteristics upon cooling after having been subjected to heating to elevated ternperatures.

5. A protected metal article comprising a metal article provided with a laminated protective coating having a fibrous layer ailixed to the metal article by an interposed adhesive layer, said fibrous layer being impregnated with a bituminous material, and an outer bituminous coating on said fibrous layer, said impregnant and said outer coating being each rendered flame retardant by the incorporation in each of at least one metallic soap insoluble in water and comprising a soap selected from the soaps of the group of metals consisting of iron, zinc, aluminum, and barium, in an amount in the range of three to fifteen per cent by Weight of the bituminous composition, said flame retarding bituminous composition being further characterized by its ability to maintain substantial predetermined physical characteristics upon cooling after having been subjected to heating to elevated temperatures.

6. A protected metal article comprising a metal article provided with a laminated protective coating having a fibrous layer aflixed to the metal article by an interposed adhesive layer, and an outer bituminous coating on said fibrous layer, said fibrous layer being impregnated with a bituminous material, said impregnant and said outer coating being each rendered flame retardant by the incorporation in each of at least one metallic soap insoluble in water and comprising a soap selected from the soaps of the group of metals consisting of manganese, iron, zinc, chromium, cobalt, aluminum, magnesium, and barium, in an amount in the range of three to fifteen per cent by weight of the bituminous composition, said flame retarding bituminous composition being further characterized by its ability to maintain substantial predetermined physicial characteristics upon cooling after having been subjected to heating to elevated temperatures.

'7. A protected metal article comprising a metal article provided with a laminated protective coating having a fibrous layer impregnated with a bituminous material and being aflixed to the metal article by a layer of bituminous adhesive, and an outer bituminous layer covering the impregnated fibrous layer, said bituminous adhesive, impregnant and outer coating each being rendered flame retardant by the incorporation therein of at least one metallic soap insoluble in water and comprising a soap-selected from the soaps o! the group ot metals consisting o! iron.

zinc, aluminum, andbarium, in an amount in the range of three to fifteen per cent by weight o f the bituminous composition, Isaid ilame'retarding bibituminous material and being aillxed to the metal article by a layer of bituminous adhesive,

Vand an outer bituminouslayer covering the impregnated fibrous layer, said bituminous adhesive, impregnant and outer coating each being rendered iiame retardant by the incorporation therein of at least one metallic soap insoluble in water and comprising a soap selected iromthe soaps of the group of metals consisting of manganese, iron, zinc, chromium, cobalt, aluminum, magnesium, and barium, in an amount in the range of three to ilfteen per cent by weight of the bituminous composition, said flame retarding bituminous composition being further characterized by its ability to maintain substantial predetermined physical characteristics upon cooling after having been subjected to heating to elevated temperatures. 

